Process for preparing a terpene phenolic condensation product

ABSTRACT

A continuous process for preparing a terpene phenolic compound by alkylating phenol with a cyclic terpene in the presence of boron trifluoride, withdrawing a resinous product characterized by its high phenol reactivity and recycling the distilled boron trifluoride and excess phenol.

United States Patent Hollis et al. [451 Sept. 19, 1972 [s41 PROCESS FOR PREPARING A [56] References Cited TERPENE PHENOLIC CONDENSATION UNITED STATES PATENTS PRODUCT 2 343 845 3/1944 P 260/619 x OWGI'S [72] Inventors: Samuel D. Hollk, Pleasant Hills, Pa.;

I Phmp E Wilma Jr Union NJ 2,59 ,235 5/1952 Geiger ..260/6l9 x [73] Assignee: Pennsylvania Industrial Che ma y Exam n rL 0n Zitver Cor oration Assistant Examiner-Norman Morgenstem 22] Filed: June 1968 AttorneyBuell, Blenko & Zxesenheun 211 Appl. No.: 739,179 [57] ABSTRACT A continuous process for preparing a terpene phenolic 52 us. Cl. ..260/619 1), 260/624 c 9 p y alkylatins p n P 11 cy p 51 Int. Cl. ..co7 37/14,C07C 39/16, C076 3/18 1n Presence of boron tylfluoflde, wltbdrawms 581 Field 6: Search ...260/6l9 D, 621, 624 A, 624 c resmous Product charactenzed by Its s phenol reactivity and recycling the distilled boron trifluoride and excess phenol.

2 Claims, No Drawings PROCESS FOR PREPARING A TERPENE PIIENOLIC CONDENSATION PRODUCT This invention relates to a continuous process for preparing a synthetic resinous product from a terpene and a phenol which product is characterized by its high phenol reactivity. This product (referred to hereinafter asa terpene phenolic compound") is useful in 'many chemical reactions and industrial processes where bisphenols are used; particularly in our process for preparing terpene epoxy resin esters as described in our co-pending application, Ser. No. 739,189, filed June 24, 1968, now 0.8. Pat. No. 3,594,340, issued July 20, 1971.

ln referring to high phenol reactivity, we mean that the substance furnishes a phenol structure inunhindered form; more specifically, that the hydroxyl group and the various positions on the phenol ring are available for reaction.

At present, it is common practice to prepare useful phenolic compounds known as bisphenols by reacting phenol with ketones, aldehydes, dihalides, terpenes and diolefins in the presence of a catalyst. The catalysts most commonly used are acid catalysts suchas sulphuric acid, phosphoric acid, acid-treated clay, hydrogen chloride, zinc chloride, boron trifluoride and the like. These catalysts must be neutralized with alkaline substances such as lime, ammonia, sodium hydroxide and the like. The neutralization reaction results in the formation of salts which must be removed either by water wash or filtration. Filtration is disadvantageous because it is time consuming and requires a second vessel to receive the filtered product. The salt cake produced by the filtration operation is usually phenol laden and elaborate disposal procedures are often required.

Frequently organic solvents are used to moderate the initial reaction of phenol with the compounds described above or to dissolve the product of the reaction. The reaction product must then be separated from the solvent by crystallization, filtration, distillation and the like. The recovered solvent must be purified to some extent to permit re-use and frequently the solvent-wet product must be dried free of solvent.

We have discovered process for producing a phenolic product having high phenol reactivity which process overcomes the disadvantages described above. In our process, no water or hydrogen halides are evolved and no catalyst salts are produced requiring water wash or filtration. Solvents are not used at any stage of the process of our invention. Moreover, our process is readily adaptable to continuous operation because no by-products are produced. The catalyst is continuously recovered and high production rates are attainable with excellent product uniformity.

We provide a process for producing a terpene phenolic compound characterized by its high phenol reactivity comprising reacting a mixture of terpene and phenol in the presence of boron trifiuoride, distilling the unreacted phenol and the boron trifluoride from the reaction mixture while withdrawing a resinous product from said reaction mixture and recycling said distilled phenol and boron trifluoride.

In the process of our invention, we prefer to admix at least oneterpene selected from the group consisting of alpha-pinene, beta-pinene, A 8 carene and turpentine with a solution of boron trifluoride in phenol to fonn a reaction mixture. The well known reaction which ensues in this admixture is the alkylation of the'phenol by the terpene. Preferably the charging ratio of molesof phenol to moles of terpene is at least 2.0 to 1 and the concentration of boron trifluoride is in the range of 0.05 to 1.5 percent by weight of the terpene utilized. Weprefer to maintain the temperature of the reaction mixture in the range of about 50 to C. during alkylation.

In the practice of our invention, an unsaturated terpene containing a cyclobutane or cyclopropane ring is added to an agitated solution of boron trifluoride in phenol while maintaining the temperature of the reaction mixture in the range of50 to 130C. If the reaction is carried out at temperatures significantly below 50 C., undesirable phenolic ethers are formed; and similarly,if the reaction temperature exceeds 130 C., the product of the reaction becomes dark in color. The terpene material used must be any one or a combination selected from the group consisting of alphapinene, beta-pinene, A carene and turpentine.

We have discovered that when excess phenol is used, it can be distilled from the product and recovered along with the boron trifluoride catalyst. Accordingly, upon the completion of the first addition of the prescribed terpene or terpenes while maintaining the temperature range described above, the reaction mixture is passed to a fractiona'ting column. There the reaction mixture may be heated under reduced pressure to cause the unreacted phenol to distill over, carrying with it all of the boron trifluoride catalyst. Part of the boron trifiuoride will condense with the phenol. The remainder can be recovered by bubbling it into fresh phenol in the trap of the vacuum system. Boron trifluoride removal is extremely effective by this technique. It has been found that no trace of the boron trifluoride remains in the product and this represents a material advantage since traces of boron trifluoride could affect subsequent chemical reactions in which the terpene phenolic compound is used.

We have found that a charging ratio of at least 2.0 to 1.0 moles of phenol to moles of terpene is required to operate the process on a continuous basis. Charging ratios below 2.0 to 1.0 result in the formation of by product oils and the like which accumulate as contaminating substances and are not recyclable. The presence of these by-products interferes with the cont'inuity of the process. Some monoalkylates and terpene phenol ethers distill over with the phenol but they rearrange and react to form normal product when recycled with the phenol.

The preferred concentration of boron trifluoride catalyst is in the range of 0.05 to 1.5 percent based on the weight of terpene utilized. It has been found that an increase in the catalyst concentration within the range specified results in an increase in the phenol reactivity of the product. Thus it is a feature of the invention that the phenol reactivity in the product can be adjusted with excellent reproducibility.

The behavior of the particular terpenesalphapinene, beta-pinene, A carene and turpentine specified for use in our invention is unique. Other terpenes and olefines react readily with phenol in the presence of boron trifluoride and the excess phenol and boron trifluorilde can be recovered by distillation as is iorosa 0643 well known, but the phenolic compounds produced do not have the high phenol reactivity exhibited by the product of the present invention. Table I below illustrates the phenol reactivity of the terpene phenolic compound produced in accordance with the invention compared withv the phenol reactivity of other alkylephenols. The commonly accepted formaldehyde reactivity was measured wherein 600 grams of each material was reacted with formaldehyde in the presence of 1.0 percent oxalic acid (dihydrate) catalyst and the softening points recorded at various levels of formaldehyde consumed. The combining ratio (in moles) of phenol to each of the alkyl groups identified in Table I was 1:1 in all cases.

The terpene phenolic compounds produced in accordance with the invention have ring and ball softening points ranging from 30 to 110 C. depending upon the reaction conditions selected. They are pale in color and soluble in methanol. These compounds are of particular value because of the enhanced reactivity which they display with chemicals which react with phenol.

to limit the invention, however, for there are numerous possible variations and modifications.

EXAMPLE I henol- F mi ture collecte w l d t th t grepara oii, mixed with fres pli n isl grfch rge sufficient lBF gas to compensate for that lost during distillation. The entire procedure was then repeated a number of times as outlined in the table below: to ascertain the behavior of the BE; and phenol when recycled.

phenol (grams) TABLE I VARIATION OF PHENOLIC RESIN SOFIENING POINT WITH MOLS OF FORMALDEHYDE CONSUMED PER MOL OF PHENOL Formaldehyde will react with these compounds to form high softening point, high solution viscosity resins which are useful in preparing varnishes and lacquers because of their desirable solubility characteristics, pale color and good color retention.

The following example will serve to illustrate the practice of our invention. The example is not intended Product softening point Fresh Alpha Recycle pinene phenol (grams) (grams) Product 0 onversion (grams) (percent) None 63. 6

This series of runs produced 1943 g. of terpene phenolic product with a yield of 98.6 percent.

While we have described a present preferred method it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously practiced within the scope of the following claims.

We claim:

1. A process for producing a reactive terpene phenolic compound characterized by its high phenol reactivity comprising the steps of a. admixing at least one terpene selected from the group consisting of alpha-pinene, beta-pinene, A carene and turpentine with a solution of boron trifluoride in phenol wherein the ratio of moles of phenol to moles of terpene is at least 2.0 to 1.0 to form a reaction mixture;

b. maintaining the temperature of said reaction mixture in the range of about 50 to C.;

c. distilling the unreacted portion of the solution of boron trifluoride in phenol from said reaction mixture;

d. withdrawing a resinuous product from said react1on mixture; and

e. recycling the distilled solution of boron trifluoride in phenol.

2. A process as recited in claim 1 in which the concentration of boron trifluoride is in the range of 0.05 to 1.5 percent by weight of the terpene utilized. 

2. A process as recited in claim 1 in which the concentration of boron trifluoride is in the range of 0.05 to 1.5 percent by weight of the terpene utilized. 